Line Regen Controller for AC Drives

Model M3345

Customer Reference Manual

TEL. (615) 244-2825

FAX (615) 244-2833

www.bonitron.com

Bonitron, Inc.

Bonitron, Inc.

An Industry Leader in AC Drive Systems and Industrial Electronics

OUR COMPANY
Bonitron is an international supplier of power controls designed to improve the performance and reliability of electronic systems and variable frequency drives. Located in Nashville, Tennessee, and founded in 1962, Bonitron has gained a reputation for designing and manufacturing products with the highest possible degree of quality and reliability. Bonitron has all the necessary resources in-house for complete electronic product development and manufacturing. Engineering facilities include a CAD lab for circuit board design and engineering labs for prototype testing and evaluation. Production facilities include production areas for circuit board assembly, a machine tool and sheet metal shop for chassis fabrication, and a systems assembly and checkout area. With these assets, Bonitron is positioned to be a leader into the future while maintaining first class support for their current customer base. Worldwide sales of equipment are generated mainly by reputation and referrals. Our customer base includes all of the major drive manufacturers, their distributors, OEMs, end users, and many other satisfied companies. Equipment is installed throughout the United States as well as in Canada, Mexico, Costa Rica, Argentina, Brazil, Chile, Venezuela, Northern Ireland, the Netherlands, Spain, Hungary, Israel, Turkey, China, India, Indonesia, Singapore, Taiwan, and the Philippines.

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Bonitron, Inc. TALENTED PEOPLE MAKING GREAT PRODUCTS

The engineering team at Bonitron has the background and expertise needed to design, develop, and manufacture the quality industrial systems demanded by todays client. A strong academic background supported by continuing education is complemented by many years of hands-on field experience. Expertise encompasses a broad range of applications and engineering solutions such as modern power conversion design techniques and microprocessor-based controls. This insures a solution tailored to the specific needs of the client. A clear advantage that Bonitron has over many competitors is combined on-site engineering labs and manufacturing facilities. This allows the engineering team to have immediate access to and response from testing and manufacturing. This not only saves time during prototype development, but also is essential to providing only the best quality products.

AC DRIVE OPTIONS
In 1975, Bonitron began working with the AC inverter drive specialists at synthetic fiber plants to develop speed control systems that could be interfaced to their plant process computers. Since that time, Bonitron has developed AC drive option modules that help overcome many of the problems encountered in applications of modern AC variable frequency drives. Bonitrons Ride-Thru module provides protection from AC line voltage sags while the Line Regen and Resistive Braking modules provide DC Bus regulation for over-voltage due to regenerated voltage. Bonitron AC drive modules are available to provide Undervoltage, Overvoltage, Line Side, Load Side, Maintenance, Power Quality, and Green / Sustainability solutions. These products are compatible with the drives of all major manufacturers and have become the standard in many industries including semiconductor, oil, and fiber.

WORLD CLASS PRODUCTS

Bonitron has developed over 3000 different modules and systems. Bonitron is willing and able to meet the unique specifications the client may request. Some Bonitron products include: Power Dip Ride-Thru Modules Power Outage Ride-Thru Modules Line Regen Modules Resistive Braking Modules Modular High Speed Precision AC Inverter Systems Inverter Upgrade Modules Multi-motor, Multi-phase Current Sensors Battery Production Charging Systems Data Acquisition Systems Process Controllers Temperature Control Systems RMS True Reading Digital Voltmeters, Ammeters, and Frequency Meters

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M3345
1. INTRODUCTION ..........................................................................................................................1
1.1. Who should use ............................................................................................................................ 1 1.2. Purpose and Scope ........................................................................................................................ 1 1.3. Manual version and change record ............................................................................................... 1 Figure 1-1: Typical M3345 Unit in the S and C Chassis................................................................... 1

2. PRODUCT DESCRIPTION.............................................................................................................2
2.1. Related Docs ................................................................................................................................. 2 2.2. Part Number Breakdown .............................................................................................................. 2 Figure 2-1: Example of M3345 Part Number Breakdown ....................................................................... 2 Table 2-1: Voltage Rating ........................................................................................................................ 3 Table 2-2: Current Ratings ....................................................................................................................... 3 Table 2-3: Chassis Styles ......................................................................................................................... 3 2.3. General Specifications Chart ........................................................................................................ 4 Table 2-4: General Specifications ............................................................................................................ 4 2.4. General Precautions and Safety Warnings ................................................................................... 5

3. INSTALLATION INSTRUCTIONS ..................................................................................................7

3.1. Environment ................................................................................................................................. 7 3.2. Unpacking ..................................................................................................................................... 7 3.3. Mounting ...................................................................................................................................... 7 Figure 3-1: M3345 Mounting Orientation................................................................................................ 8 3.4. Wiring and Customer Connections ............................................................................................... 9 3.4.1. Power Wiring ........................................................................................................................ 9 Table 3-1: Power Terminal Specifications 10 to 45 Amp Chassis ...................................................... 10 Table 3-2: Power Terminal Specifications 60&90 Amp Chassis ........................................................ 10 Table 3-3: Power Terminal Specifications 120 Amp Chassis ............................................................. 10 3.4.2. I/O Wiring ........................................................................................................................... 10 Table 3-4: I/O Terminal Specifications S Chassis............................................................................... 10 Table 3-5: I/O Terminal Specifications B and X Chassis .................................................................. 11 Table 3-6: I/O Terminal Specifications Y, C, W, Z, and V Chassis.................................................... 11 Figure 3-2: S Chassis Connections ..................................................................................................... 11 Figure 3-3: W Chassis Connections.................................................................................................... 11 Figure 3-4: V Chassis Connections .................................................................................................... 12 Figure 3-5: X and B Chassis Connections....................................................................................... 12
Figure 3-6: 60&90 Amp C Chx Conn. ........................................................................................... 12 Figure 3-7: 120 Amp C Chx Conn...................................................................................................... 12 Figure 3-8: Y and Z Chassis Connections ....................................................................................... 12

3.5. Typical Configurations ............................................................................................................... 12 Figure 3-9: M3345 10-120 Amp Single Drive / Regen Field Wiring Diagram...................................... 13 Figure 3-10: M3345 Multiple Drives/ Regens Field Wiring Diagram ................................................... 14 Figure 3-11: M3345 Master Slave I/O Connection Diagram ................................................................. 15 Figure 3-12: Control Board & Jumper Configuration ............................................................................ 16

4. OPERATION ..............................................................................................................................17
4.1. Functional Description ............................................................................................................... 17 4.2. Features....................................................................................................................................... 17 4.2.1. Fusing .................................................................................................................................. 17 4.2.2. Internal Line Filtering ......................................................................................................... 17 4.2.3. Indicators............................................................................................................................. 18 4.2.4. Status Contact ..................................................................................................................... 18 4.2.5. I/O For Paralleling Regens .................................................................................................. 18

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Table of Contents
4.3. Startup......................................................................................................................................... 19 4.3.1. Pre-power Checks ............................................................................................................... 19 4.3.2. Startup Procedure and Checks ............................................................................................ 19 4.3.3. Cooling Fan ......................................................................................................................... 19 4.4. Operational Adjustments ............................................................................................................ 19 4.4.1. Control Board Adjustments ................................................................................................ 19 4.4.2. Voltage Dip Threshold ........................................................................................................ 20 4.4.3. Bias Adjustment .................................................................................................................. 20 4.4.4. Overload Limit .................................................................................................................... 20

5. MAINTENANCE AND TROUBLESHOOTING ...............................................................................21

5.1. Periodic Testing .......................................................................................................................... 21 5.2. Maintenance Items ...................................................................................................................... 21 5.3. Troubleshooting .......................................................................................................................... 21 5.3.1. POWER lamp is out: ........................................................................................................... 21 5.3.2. RUN light is out .................................................................................................................. 21 5.3.3. Status Contact remains open after a 5 second delay ........................................................... 22 5.3.4. Meter showing excessive current when in standby ( >3% rated current) ........................... 22 5.3.5. Drive trips on DC Bus Overvoltage .................................................................................... 22 5.3.6. OVERLOAD light is flickering .......................................................................................... 22 5.3.7. CURRENT LIMIT light is on ............................................................................................. 22 5.3.8. Technical Help before you call ........................................................................................ 23

6. ENGINEERING DATA ................................................................................................................25

6.1. Ratings Charts............................................................................................................................. 25 Table 6-1: Ratings and Specifications 230VAC ................................................................................. 25 Table 6-2: Ratings and Specifications 380VAC ................................................................................. 26 Table 6-3: Ratings and Specifications 460VAC ................................................................................. 27 6.2. Watt Loss .................................................................................................................................... 28 6.3. Certifications .............................................................................................................................. 28 6.4. Fuse/Circuit Breaker Sizing and Rating ..................................................................................... 28 Table 6-4: Replacement Fuses ............................................................................................................... 28 6.5. Dimensions and Mechanical Drawings ...................................................................................... 29 Figure 6-1: M3345 S Chassis Dimensional Outline ........................................................................... 29 Figure 6-2: M3345 W Chassis Dimensional Outline .......................................................................... 30 Figure 6-3: M3345 V Chassis Dimensional Outline ........................................................................... 31 Figure 6-4: M3345 B Chassis Dimensional Outline ........................................................................... 32 Figure 6-5: M3345 B Chassis with Fan Dimensional Outline ............................................................ 33 Figure 6-6: M3345 C Chassis Dimensional Outline ........................................................................... 34 Figure 6-7: M3345 X Chassis Dimensional Outline ........................................................................... 35 Figure 6-8: M3345 X Chassis with Fan Dimensional Outline ............................................................ 36 Figure 6-9: M3345 Y Chassis Dimensional Outline ........................................................................... 37 Figure 6-10: M3345 Z Chassis Dimensional Outline ......................................................................... 38 6.6. Block Diagram ............................................................................................................................ 39 Figure 6-11: Line Regen Functional Block Diagram ............................................................................. 39

7. APPENDIX.................................................................................................................................41
7.1. Application Notes ....................................................................................................................... 41 7.1.1. Sizing the Line Regeneration Control ................................................................................. 41 7.1.2. Calculating Energy Savings ................................................................................................ 41 7.1.3. Savings Example ................................................................................................................. 42

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Users Manual
1. INTRODUCTION
1.1. WHO SHOULD USE
This manual is intended for use by anyone who is responsible for integrating, installing, maintaining, troubleshooting, or using this equipment with any AC Drive System. Please keep this manual for future reference.

1.2. PURPOSE AND SCOPE

This manual is a users guide for the Model M3345 Line Regen Control modules. It provides you with the necessary information to successfully install and use the M3345 modules in your application. In the event of any conflict between this document and any publication and/or documentation related to the application, the latter shall have precedence.

1.3. MANUAL VERSION AND CHANGE RECORD

Ratings Charts are updated in Rev 05a. Figure 1-1: Typical M3345 Unit in the S and C Chassis

M3345
2. PRODUCT DESCRIPTION
The need for regenerated voltage control occurs when the frequency of an AC motor is greater than the frequency of the AC line or variable frequency drive providing power to the motor. In this case, the motor acts as a generator. The energy generated by a motor must be dissipated or returned to the power source. If this energy is not controlled, the motor may run with high voltage, the energy may be dissipated as heat in the motor, or the drive may trip on an overvoltage condition. Bonitrons Model 3345 Regen Module is used for regeneration control of any AC drive system that uses a fixed bus system, such as the bus system used on AC PWM drives. The Regen module can pass the regenerated energy from the DC bus of the drive to the AC line. This provides for regulation of the DC bus and prevents the drives from tripping on overvoltage. When a dynamic braking resistor is used with a PWM drive, the regenerated energy is dissipated as heat and energy is wasted. When the Model 3345 Regen Module is used, the regenerated energy is returned to the input AC line with near unity power factor. Substantial energy savings may occur as the regenerated energy can be used to power other equipment.

2.1. RELATED DOCS

M3345D Diode Sharing Modules (for multiple drive applications). M3575T Transistor Modules (low duty applications and redundant operation with a Regen Module). M3575R Resistive Braking Load (used in conjunction with M3575T modules).

2.2. PART NUMBER BREAKDOWN

Figure 2-1: Example of M3345 Part Number Breakdown M3345 BASE MODEL NUMBER VOLTAGE RATING CURRENT RATING CHASSIS STYLE CURRENT METER COOLING FAN SPECIAL OPTIONS FREQUENCY 4 1 S M F 0 50HZ

BASE MODEL NUMBER

The Base Model Number for all Line Regen Controllers is M3345.

VOLTAGE RATING
A 1 digit code represents the 3 AC line input voltage to the Regen module. The voltage rating must be selected for the system voltage that will be applied.

Users Manual
Table 2-1: Voltage Rating

RATING CODE
2 3 4

VOLTAGE
230VAC 380VAC 460VAC

CURRENT RATING
A 1-digit code represents the maximum DC current which the Regen module can dissipate. This is an absolute maximum rating. Table 2-2: Current Ratings

RATING CODE
0 1 2 4 A 5 6

CURRENT
10 Amps 20 Amps 30 Amps 45 Amps 60 Amps 90 Amps 120 Amps

CHASSIS STYLE
Table 2-3: Chassis Styles

CHASSIS CODE
S (10-45 Amps) B (10-45 Amps) X (10-45 Amps) Y (30-90 Amps) C (30-120 Amps) W (60-90 Amps) Z (60-120 Amps) V (120 Amps)

DESCRIPTION
Type-1 enclosure Type-13 JIC type wall mount enclosure Open chassis, panel mount backplate Open chassis, panel mount backplate Type-13 JIC type wall mount enclosure Type-1 enclosure Open chassis, panel mount backplate Type-1 enclosure

SIZE (H X W X D)
17.75 x 6 x 11 without fan: 17.50 x 16.25 x 8.25 with fan: 17.50 x 18.50 x 8.25 without fan: 15.00 x 15.10 x 8.50 with fan: 15.00 x 18.00 x 8.50 16.00 x 20.00 x 11.00 26.50 x 23.00 x 10.50 20 x 10 x 10.5 24.00 x 20.00 x 11.00 27 x 10 x 14.5

Type-1 may also be known as bookshelf. See Section 6.5 for chassis mounting and dimensional outlines.

CURRENT METER
An M in this position indicates the inclusion of a DC Regen current meter with the Regen module. A 0 in this position will omit the meter. A meter is provided as a standard part of all Type-13 JIC chassis modules and Type-1 chassis modules and is optional for all open-chassis modules.

M3345
COOLING FAN
An F in this position indicates the inclusion of a cooling fan with the Regen module. A 0 in this position will omit the cooling fan. A cooling fan is provided as a standard part of all chassis types except for the B and X chassis modules; however the cooling fan is an available option for the B and X chassis modules. Please note that a Regen modules rating is somewhat dependant on the use of a cooling fan. Refer to the tables in Section 6 of this manual to determine if a cooling fan is required for your application.

SPECIAL OPTIONS
A 0 in this position indicates the unit is not Master / Slave selectable. An M in this position indicates the unit is 60A or higher and is Master / Slave selectable. Units with current ratings of 60-120 Amps will support Master/Slave operation. ATTENTION! Units with current ratings of 10-45 Amps will not support Master/Slave operation.

FREQUENCY
If the unit is for use on 60Hz systems, omit this position. 50Hz in this position indicates the unit is for use on 50Hz systems.

2.3. GENERAL SPECIFICATIONS CHART

Table 2-4: General Specifications

PARAMETER

SPECIFICATION
Input AC Line Three Phase Rated Voltage 10% 50Hz or 60Hz Drive DC Bus 100% of rated DC current Ground Greater than 90% 100% DC Rating 0 to +40C -20 to +65 C Below 90% Non-condensing Free of corrosive or conductive gas and dust Power Light Run Current Limit Overload Current Meter Ready

Connections

Power Factor Current Limit Operating Temp Storage Temp Humidity Atmosphere

Status Indicators

I/O

Users Manual
2.4. GENERAL PRECAUTIONS AND SAFETY WARNINGS
HIGH
VOLTAGES MAY BE PRESENT!

NEVER

ATTEMPT TO OPERATE THIS PRODUCT WITH THE ACCESS DOORS OR COVERS OPENED! ATTEMPT TO SERVICE THIS PRODUCT WITHOUT FIRST DISCONNECTING POWER TO AND FROM THE UNIT!

NEVER DANGER!

FAILURE

TO HEED THESE WARNINGS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH!

HIGH AMBIENT

THIS THIS

PRODUCT WILL GENERATE TEMPERATURES DURING OPERATION.

PRODUCT SHOULD BE INSTALLED ON A NONFLAMMABLE SURFACE WITH CLEARANCES OF AT LEAST TWO INCHES IN ALL DIRECTIONS. ALLOW AMPLE TIME FOR THE UNIT TO COOL BEFORE ATTEMPTING SERVICE ON THIS PRODUCT.

ALWAYS CAUTION! BEFORE

ATTEMPTING INSTALLATION OR REMOVAL OF THIS PRODUCT, BE SURE TO REVIEW ALL DRIVE AND/OR RESISTIVE LOAD DOCUMENTATION FOR PERTINENT SAFETY PRECAUTIONS.

INSTALLATION

AND/OR REMOVAL OF THIS PRODUCT SHOULD ONLY BE ACCOMPLISHED BY A QUALIFIED NATIONAL ELECTRICIAN IN ACCORDANCE WITH ELECTRICAL CODE OR EQUIVALENT REGULATIONS.

ANY QUESTIONS AS TO APPLICATION, INSTALLATION OR SERVICE SAFETY SHOULD BE DIRECTED TO THE EQUIPMENT SUPPLIER.

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Users Manual
3. INSTALLATION INSTRUCTIONS
CAUTION!

Installation and/or removal of this product should only be performed by a qualified electrician in accordance with National Electrical Code or local codes and regulations.

Proper installation of the M3345 Regen Modules should be accomplished following the steps outlined below. Be sure to refer to the AC Drive instruction manual as these steps are performed. Please direct all installation inquiries that may arise during the installation and start up of this product to the equipment supplier or system integrator.

3.1. ENVIRONMENT
The module should be installed in an area protected from moisture and falling debris. Buildup of dust or debris may cause poor performance and possibly a failure. Operating in a wet environment can pose a shock hazard. The recommended temperature range for operating this module is 0 to +40C.

3.2. UNPACKING
Upon receipt of this product, please verify that the product received matches the product that was ordered and that there is no obvious physical damage to the unit. If the wrong product was received or the product is damaged in any way, please contact the supplier from which the product was purchased.

3.3. MOUNTING
The installation site for the module should be chosen with several considerations in mind: When mounting Regen units in an enclosure, power dissipation should be taken into account. Refer to Section 6.2 Watt Loss for details. The unit requires a minimum clearance of two (2) inches in all directions around it when mounted near a non-heat source. Unit should not be exposed to falling debris or condensation. Once the installation site has been selected as outlined above, the unit should be mounted in place. The M3345 must be properly oriented for proper heat flow through the unit. The M3345 must be mounted with the rear surface of the unit to the mounting surface. Unit may be mounted vertically or horizontally as shown in Figure 3-1A. Do Not mount the unit in an upside-down position or on the underside of a mounting surface as shown in Figure 3-1B. Do Not mount the unit in a horizontal position with its side parallel to the mounting surface or floor as shown in Figure 3-1C. Refer to Table 2-3: Chassis Styles in Section 2.2 of this manual to determine the chassis for the unit. Mounting dimensions and provisions vary by unit chassis. See Figure 3-1 for Mounting Orientation information and Section 6.5 for dimensional drawings.

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HANGING UNDERSIDE
UP UP UP

M3345

Figure 3-1: M3345 Mounting Orientation

Dwg #: 070131 Rev: 20070524

VERTICAL SURFACE

HORIZONTAL SURFACE

HORIZONTAL TO FLOOR

Users Manual
3.4. WIRING AND CUSTOMER CONNECTIONS
Be sure to review all pertinent AC Drive and system documentation as well as the information listed below before proceeding. Connection points and terminal numbers of the AC drive will be found in the documentation provided with those units. See Tables 3-1 thru 3-6 and Figures 3-2 thru 3-11 for connection details.

3.4.1.

POWER WIRING
Only qualified electricians should perform and maintain the interconnection wiring of this product. All wiring should be in accordance with local codes.

WARNING!

3.4.1.1.

Where possible, minimize the wire length between the Regen and the Drive. The wire length should not exceed 10. Avoid routing and bundling the Regen AC/DC wire with the Drive AC PWM motor output wiring. 3 PHASE AC INPUT The AC input should be connected to a 3-phase source following the typical guidelines used when sizing for an inverter. This will insure sufficient source impedance to return power to the grid. Do not install chokes or reactors between the regen and the power source. If the AC drive requires a line reactor, the Regen should be connected to the utility grid side. If an isolation transformer is to be used, the regen AC input MUST be connected to the same point as the drive AC input. Do not connect to a generator unless minimum load at any time exceeds the peak expected regen power. The regen units are not phase sensitive. Insure that the frequency of the unit is correct when ordered, and only use 60Hz units on 60Hz systems, 50Hz units on 50Hz systems. This frequency is specified when the unit is ordered, and cannot be changed in the field.

Installing 50Hz regen units on 60Hz systems may cause severe damage to the regen unit.
WARNING!

3.4.1.2.

DC BUS INPUT
The DC bus input may be connected to the DC bus of an AC drive, the DC output of a diode sharing unit, or to a common DC bus. If a reactor or choke are being used in the bus, make sure the actual connection is in parallel with filter capacitors of the drive/inverter.

Never attach the DC bus input of the M3345 to braking terminals on the AC drive, commonly marked BR. These terminals are intended for use with an external resistor, and are not directly connected to the bus filter capacitors of the drive. Damage may occur if these terminals are used. WARNING! Please refer to your AC drive manual or AC drive Technical Support department for assistance with this connection.

M3345
3.4.1.3.

GROUNDING
Using the ground stud provided, ground the chassis in accordance with local codes. Typically the wire gauge will be the same as is used to ground the attached drive.

Table 3-1: Power Terminal Specifications 10 to 45 Amp Chassis

TERMINALS
L1, L2, L3 + GND

FUNCTION
Power Input DC Bus Input Chassis Ground

ELECTRICAL RATINGS
45A 230/460VAC 45A 750VDC

WIRE SIZE
#10-32 screw #10-32 screw #10-32 screw

TORQUE
20 in-lbs 20 in-lbs 20 in-lbs

Table 3-2: Power Terminal Specifications 60&90 Amp Chassis

TERMINALS
L1, L2, L3 + GND

FUNCTION
Power Input DC Bus Input Chassis Ground

ELECTRICAL RATINGS
90A 230/460VAC 90A 750VDC

WIRE SIZE
5/16 stud 5/16 stud 5/16 stud

TORQUE
100 in-lbs 100 in-lbs 100 in-lbs

Table 3-3: Power Terminal Specifications 120 Amp Chassis

TERMINALS
L1, L2, L3 + GND

FUNCTION
Power Input DC Bus Input Chassis Ground

ELECTRICAL RATINGS
120A 230/460VAC 120A 750VDC

WIRE SIZE
3/8 stud 3/8 stud 5/16 stud

TORQUE
182 in-lbs 182 in-lbs 100 in-lbs

3.4.2.

I/O WIRING
M3345 Line Regens come with a status contact. Master/Slave I/O terminals. See Table 3-6 for

3.4.2.1.

STATUS CONTACT
This is an isolated normally open contact. Contact will energize closed upon ready condition of unit. Contact is rated for 120V AC/DC @ 2 amps. See Section 4.2.4 for more information. Table 3-4: I/O Terminal Specifications S Chassis

TERMINAL
TS1-1 TS1-2 TS1-3

FUNCTION
Ready Contact Common Ready Contact No Connection Ready Contact N.O.

ELECTRICAL RATINGS
2A - 120V resistive

WIRE SIZE
28-16 AWG

TORQUE
2 in-lbs

2A 120V resistive

28-16 AWG

2 in-lbs

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Users Manual
Table 3-5: I/O Terminal Specifications B and X Chassis

TERMINAL
TB4-1 TB4-2 TB4-3

FUNCTION
Ready Contact N.C. Ready Contact N.O. Ready Contact Common

ELECTRICAL RATINGS
2A - 120V resistive 2A - 120V resistive 2A - 120V resistive

WIRE SIZE
18-12 AWG 18-12 AWG 18-12 AWG

TORQUE
4.5 in-lbs 4.5 in-lbs 4.5 in-lbs

3.4.2.2.

MASTER / SLAVE I/O

Units that are rated 60 amps and greater are provided with Master / Slave I/O terminals for parallel operation. See Figure 3-11 and Section 4.2.5 for more information. Reference Table 3-6 when the unit is configured for Master.

Table 3-6: I/O Terminal Specifications Y, C, W, Z, and V Chassis

TERMINAL
TS1-1 TS1-2 TS1-3 TS1-4 TS1-5* TS1-6*

FUNCTION
Master / Slave + Master / Slave Ready Contact NO

ELECTRICAL RATINGS WIRE SIZE

.5A 250V .5A 250V 2A - 120V resistive 18-12 AWG 18-12 AWG 18-12 AWG

TORQUE
20 in-lbs 20 in-lbs 20 in-lbs

*Not standard in the Y chassis. Figure 3-2: S Chassis Connections Figure 3-3: W Chassis Connections

Dwg #s: 070133, 070134 Rev: 20080313

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M3345
Figure 3-4: V Chassis Connections Figure 3-5: X and B Chassis Connections

Figure 3-6: 60&90 Amp C Chx Conn.

Figure 3-7: 120 Amp C Chx Conn.

Figure 3-8: Y and Z Chassis Connections

3.5. TYPICAL CONFIGURATIONS

The diagrams shown in Figures 3-9 thru 3-11 illustrate typical connections of the M3345 Regen units with generic VFDs. There are many other configurations that may be applied providing a basic connection criterion is maintained such as: The AC input should maintain a low impedance path back to the grid. No reactors should be connected upstream of the regen unit without consulting Bonitron for instructions.

12

Dwg #s: 080109, 080110

Rev: 20080219 and 080108, 080130, 070135 Rev 20080313

Users Manual
The DC input should be connected to a fixed bus whether from a common bus supply or from the output of a VFD. This should never be connected to a switching source such as the braking resistor terminals on some drives. The DC input should not be connected to an active SCR front end drive without instructions from Bonitron.

Figure 3-9: M3345 10-120 Amp Single Drive / Regen Field Wiring Diagram

Dwg #: 010132 Rev: 20070521

13

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*MASTER/SLAVE & STATUS I/O 60A, 90A & 120A ONLY
POWER POWER POWER

M3345

MODEL 3345 REGEN

*MASTER
1 2 3 4 5 6 1 2 3 4 5 6
RUN
STOP RUN

MODEL 3345 REGEN

*SLAVE1

MODEL 3345 REGEN

*SLAVE2
1 2 3 4 5 6

RPM
0 5 6 7 8 9 1 2 3 4

HZ

TYPICAL MOTOR AND DRIVE

AC LINE DC BUS AC LINE DC BUS

L1 L2 L3 DC BUS

DRIVE 1
T1 T2 T3 GND

AC LINE

DC BUS

RUN RPM
0 5 6 7 8 9 1 2 3 4

STOP

RUN

HZ

TYPICAL MOTOR AND DRIVE

L1 L2 L3 DC BUS

Figure 3-10: M3345 Multiple Drives/ Regens Field Wiring Diagram

Dwg #: 950175 Rev: 20070522

DRIVE 2
T1 T2 T3 GND

DC ( - ) DRIVE 1 DC ( - ) DRIVE 2 DC ( - ) DRIVE 3 DC ( - )

REGEN NEG.

RUN RPM
0 5 6 7 8 9 1 2 3 4

STOP

RUN

HZ

TYPICAL MOTOR AND DRIVE

TYPICAL M3345D
DRIVE 1 DC ( + ) DRIVE 2 DC ( + ) DRIVE 3 DC ( + ) DC ( + )

L1 L2 L3 DC BUS

DRIVE 3
T1 T2 T3 GND

REGEN POS.

L1

L2

L3

AC LINE

MASTER 1st SLAVE

M-S I/O STATUS

2nd SLAVE
M-S I/O STATUS

M-S I/O

STATUS

1 2 3 4 5 6

1 2 3 4 5 6

1 2 3 4 5 6

3rd SLAVE
M-S I/O STATUS

4th SLAVE
M-S I/O STATUS

Figure 3-11: M3345 Master Slave I/O Connection Diagram

Dwg #: 070129 Rev: 20070522

1 2 3 4 5 6

1 2 3 4 5 6

Users Manual

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M3345
Figure 3-12: Control Board & Jumper Configuration For Single unit or Master operation J1 & J2 must be in the M position. For Slave operation J1 & J2 must be in the S position.
J2

OVERLOAD

R118

S M J1

BIAS ADJUST

RUN/STDBY

I-LIMIT LD2

LD1

16

DIP ADJUST

R82

R159

SLOPE

OVER LOAD

LD3

R89

Users Manual
4. OPERATION
4.1. FUNCTIONAL DESCRIPTION
The M3345 Line Regen enables energy being generated by an over-hauling motor to be efficiently returned to the power grid. Alternative solutions typically consist of dissipating the returned energy in a resistor or simply allowing the motor to coast uncontrolled to a stop. The M3345 Line Regen establishes a reference from the power source connected to the 3 phase input. This reference is used to establish the actual rectified DC voltage which is equal to the DC bus of the AC Drive in standby. The DC reference allows for conduction back to the AC line with limited rise in DC bus voltage. The reference is also used to monitor instantaneous changes in the incoming voltage. Instantaneous changes in voltage greater than 15% can create an over-power condition for the power semiconductors. The M3345 will go into a shutdown mode during such events and resume operation upon return of nominal voltage. The M3345 will also go into the shutdown mode upon loss of any phase of the incoming power. The M3345 series of Regen Modules come standard with an internal bus structure which allows for regeneration from the drive to the AC Line only. Power may be transferred from the AC drive to the regen; however, the regen will not provide energy to the AC drive.

4.2. FEATURES
Fusing Internal line filtering Current metering Power indicator Status contact I/O for paralleling 60, 90, and 120 Amp units

4.2.1.

FUSING
The M3345 Line Regen is provided with fusing for the AC input and the DC bus input. All fuses are fast semiconductor type and should only be replaced with original type. Please refer to Table 6-4 in Section 6.4.

4.2.2.

INTERNAL LINE FILTERING

The M3345 series Line Regen incorporates internal filtering on the AC line to remove voltage transients created by the internal transistors. It also adds additional filtering to noise and harmonics that may be generated outside of the regen. The internal filtering is not intended for filtering external harmonics and if there are any known power quality issues extra attention should be given when startups are performed.

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M3345
4.2.3.

INDICATORS
CURRENT METERING
The M3345 Line Regen may come with an ammeter installed. This is an averaging meter which may not deflect the instantaneous current peaks which may be present.

4.2.3.1.

4.2.3.2.

POWER INDICATOR
The M3345 Line Regen comes standard with a neon power lamp. This lamp is powered by 2 of the 3 phases feeding the AC input. This lamp should not be relied upon for determining if voltage is present! Always check for voltage with dependable measuring device before attempting service on unit.

CAUTION!

4.2.4.

STATUS CONTACT
The M3345 Line Regens come equipped with a status contact which may be integrated into system control I/O. This contact is normally open and energized closed when ready. The contact will open upon any of the following events: Loss of AC voltage Loss of any phase Instantaneous change in voltage Overload condition Over-temperature This contact can be used for remote indication of the operation of the unit.

4.2.5.

I/O FOR PARALLELING REGENS

The M3345 regeneration units come equipped with Master / Slave selectable control boards. Units >60 Amp are available for Master/Slave operations. The S, B, and X chassis units (< 60 Amp) do not provide I/O connections for Master / Slave operation. It is imperative that when paralleling units, one unit be configured as a Master and all others configured as Slaves. This will allow for up to 4 Slaves and 1 Master unit to be used in parallel operation. Refer to Figure 3-11 for connection diagram. Consult with Bonitron if you plan to configure more than 3 units as Slaves on the 60 & 90 Amp units. Consult with Bonitron if you plan to configure more than 2 units as Slaves on the 120 Amp unit. When a unit is configured as Master, the terminals appear as outputs to the other units. When the unit is configured as Slave, the terminals appear as inputs to the other units. The signal is a complex waveform that is not reproducible as an analog input or output. The signal is floating with respect to ground, and could have a significant potential difference from other references. Do not attempt to use these signals for any purpose other than interconnecting Bonitron M3345 units! Damage may occur to the M3345 as well as to the connected equipment!

WARNING!

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Users Manual
4.3. STARTUP
This section covers basic checks and procedures that should be used when performing a startup with a M3345 Line Regen.

4.3.1.

PRE-POWER CHECKS
Insure that the frequency of the AC power system is the same as the regen unit. Insure that the voltage of the AC power system is the same as the regen unit. Insure that all connections are tight and that all wiring is of the proper size and rating for operation. Verify continuity of all input fuses prior to applying power. Check for exposed conductors that may lead to inadvertent contact. Check for any debris, shavings, trimmings, etc that may cause shorts or obstruct ventilation on unit.

4.3.2.

STARTUP PROCEDURE AND CHECKS

After completing Regen pre-checks and recommended checks for connected equipment you may apply power to the system. The power indicator on the front panel should illuminate and a small amount of current may be noticed on the ammeter. If the cover is open, the RUN LED should be illuminated on the 3345C2 control board (see Figure 3-12 for location). Status contact should be closed after a 2 second delay, which is an indication that unit is ready for operation. If any of the following conditions exist, refer to Troubleshooting in Section 5.3. Front panel lamp off with power applied. Status contact still open after 5 seconds. Excessive current flow in standby mode. If none of the above conditions exist, the Regen Unit is now ready to operate, and the drive system can be run normally.

4.3.3.

COOLING FAN
A heat sink cooling fan may be supplied as part of the Regen unit. The fan runs continuously when proper system voltage is present at the Regen unit inputs.

4.4. OPERATIONAL ADJUSTMENTS

Adjustments made outside of the factory settings can cause poor performance, reduced system capability, heatsink overheating, or even component failures. Under severe operating conditions, or if the settings have been accidentally or intentionally altered, some minor WARNING! field adjustment may be required. It is recommended that you consult Bonitron prior to making any adjustments.

4.4.1.

CONTROL BOARD ADJUSTMENTS

These pots are factory preset and should not require adjustments at startup. Please contact Bonitron prior to making adjustments.

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M3345
4.4.2.

VOLTAGE DIP THRESHOLD

The voltage dip sensing circuit monitors the incoming power and will activate the shutdown circuit if the AC voltage feeding the system incurs an instantaneous drop of more than 15%. R82 is used to adjust the percent dip that may be allowed without initiating a shutdown. The following steps will enable potentiometer R82 to be returned to near factory setting: Locate R82 on the control board and turn CCW until the Run LED goes OFF. 1. Turn R82 slowly CW until the Run LED just comes ON. 2. Continue to turn CW 1.5 more turns, and leave it set.

4.4.3.

BIAS ADJUSTMENT
This potentiometer sets the knee of the bias curve between the tracking DC bus reference and the DC bus feedback. It is normally set to conduct a small amount of trickle current from the drive, while the drive is in a STANDBY mode (powered with no running motors or with unloaded motors). See Figure 3-12 for location of R89 for adjustment. The following steps will enable potentiometer R89 to be returned to near factory setting. 1. Turn R89 CW about 5 turns. 2. Monitor the DC ammeter located on the front panel of the Regen module (or a DC clamp ammeter if meter is not installed). 3. Turn R89 slowly CCW until approximately 3% of the Regen module current rating is achieved, and then leave it set. Note: This setting may change based on the stability of the system 3-phase AC line voltage. It is not necessary to keep the trickle current in tight adjustment, as it will vary with the system voltage.

4.4.4.

OVERLOAD LIMIT
R118 potentiometer is used to adjust the maximum amount of drive DC bus rise above the regen module DC bus reference which allows 100% of the regen module rated current to flow. Improper field adjustment of this pot may result in device failure from excessive power dissipation in the transistors. Do not adjust without consulting Bonitron!

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Users Manual
5. MAINTENANCE AND TROUBLESHOOTING
Repairs or modifications to this equipment are to be performed by Bonitron approved personnel only. Any repair or modification to this equipment by personnel not approved by Bonitron will void any warranty remaining on this unit.

5.1. PERIODIC TESTING

There are no requirements for periodic testing of these units. It may be beneficial to repeat start-up procedures and checks when performing routine maintenance.

5.2. MAINTENANCE ITEMS

Check the fan periodically for debris, and blow out with an air hose if it has become obstructed or not running at full capacity. Power should not be applied when blowing dust and debris out of unit.

5.3. TROUBLESHOOTING
There are no user serviceable parts within the M3345 Regen unit. If you are still experiencing problems after you have reviewed this whole Section you may contact Bonitron for additional assistance at (615) 244-2825.

CAUTION!

The 3345C2 Control Board has 3 LEDs which may be useful in diagnosing problems with the unit or system. The cover may need to be removed in order to access the control board. Do not remove any covers with power applied to the unit! Refer to Figure 3-12 for location of the LEDs on the circuit board. Following is a brief description of the LEDs and indications:

5.3.1.

POWER LAMP IS OUT:

Check AC input voltage at fuses Check voltage at output side of fuses Check connection to lamp from PCB

5.3.2.

RUN LIGHT IS OUT

The RUN LED indicates that the module is enabled and in a ready condition. This LED is directly related to the status contact at the I/O terminal. If the RUN LED is ON the status contact should be closed. If the LED is ON and the status contact does not change there is most likely a wiring issue. When the power is applied to the module, the RUN LED will normally come ON after a startup delay of approximately 2 seconds. Thereafter, the RUN LED should be ON, indicating that the system is ready to operate. If the RUN LED fails to come ON, one of several faults may be indicated. If the OVERLOAD LED is lit or briefly comes on other than at powerup, refer to Section 5.3.6. If no LEDs are lit, remove power and unplug TB2 and measure continuity of the purple and purple/tr wires on the connector. This should be 0 ohms. If connection measures open, the thermostat is either indicating high temperature or is defective. Switch opens at 175F and closes at 140F on all chassis EXCEPT the Y chassis

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M3345
(where the switch opens at 140F and closes at 110F). If the unit is cool, the switch may be defective. Contact Bonitron for service. Check the ribbon cable connector CN1 to be securely plugged in. If thermostat measures OK, check the continuity of the wires feeding the 3 phase AC to the control board at TB1. The brown, yellow, and orange wires should be directly connected to the main input fuses. Verify the Dip Threshold as shown in Section 4.4.2. Check AC input voltage at fuses to be within +/- 10% of nominal voltage If unit appears to be hot allow a few minutes to cool off If status contact does not change try cycling power to the unit

5.3.3.

STATUS CONTACT REMAINS OPEN AFTER A 5 SECOND DELAY

5.3.4.

METER SHOWING EXCESSIVE CURRENT WHEN IN STANDBY ( >3% RATED CURRENT)

Measure AC input voltage to be balanced Line to Line If more than 5VAC difference, move highest pair to B & C Check for harmonics and noise on the AC that may be caused by DC drives, welders, induction heaters, etc. See Section 4.4 about adjustments and/or contact support at Bonitron Verify status contact, if open see Section 5.3.3 Check DC bus voltage at fuses Check DC bus polarity at fuse Check DC bus fuses Ensure unit is not overheated Verify proper sizing of regen unit

5.3.5.

DRIVE TRIPS ON DC BUS OVERVOLTAGE

5.3.6.

OVERLOAD LIGHT IS FLICKERING

The normal state for the OVERLOAD LED is OFF. The OVERLOAD LED may flash for a brief moment on power-up. The OVERLOAD LED indicates that the system DC bus feedback is substantially greater than the DC bus reference signal. Under normal operating conditions, this occurs when the regenerated power from the drive is greater than the capacity of the regen module. When this occurs, the DC bus rise will cause the regen module to be temporarily disabled. With the module disabled, the drive DC bus will continue to rise until the Drive Overvoltage condition causes the drive to trip OFF. Once the Overvoltage condition ceases to exist, the OVERLOAD LED will turn OFF and the fault condition will be reset. Since the drive and regen module have peak rectifier diode modules, a substantial line transient on the AC power lines can cause an erroneous OVERLOAD fault even in the standby mode.

5.3.7.

CURRENT LIMIT LIGHT IS ON

The normal state for the CURRENT LIMIT LED is OFF. An ON state for the CURRENT LIMIT LED indicates that there is greater than 100% of the maximum limit of instantaneous, non-filtered, regenerated current in any 1 of the 3 AC input line feeds. The response of the CURRENT LIMIT LED is much quicker than the averaging DC bus ammeter frequently supplied with

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Users Manual
the regen module. The CURRENT LIMIT LED is informative when the system operation consists of short but high peak currents. An ON state can indicate the presence of short energy surges which may cause an Overload condition.

5.3.8.

TECHNICAL HELP BEFORE YOU CALL

If technical help is required, please have the following information available when calling: Model number of unit Serial number of unit Name of original equipment supplier if available Record the Line to Line voltage on all 3 phases Record the DC bus voltage immediately after the AC voltage Brief description of the application Drive and motor hp or kW KVA rating of power source Source configuration Wye/Delta and grounding

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6. ENGINEERING DATA
6.1. RATINGS CHARTS
Table 6-1: Ratings and Specifications 230VAC

MODEL NUMBERS
M3345-20SMF0 M3345-20X*00 M3345-20X*F0 M3345-20BM00 M3345-20BMF0 M3345-21SMF0 M3345-21X*00 M3345-21X*F0 M3345-21BM00 M3345-21BMF0 M3345-22SMF0 M3345-22X*00 M3345-22X*F0 M3345-22BM00 M3345-22BMF0 M3345-22CMFM M3345-22Y*F0 M3345-24SMF0 M3345-24X*00 M3345-24X*F0 M3345-24BM00 M3345-24BMF0 M3345-24CMFM M3345-24Y*F0 M3345-2AWMFM M3345-2AY*FM M3345-2ACMFM M3345-2AZ*FM M3345-25WMFM M3345-25Y*FM M3345-25CMFM M3345-25Z*FM M3345-26VMFM M3345-26CMFM M3345-26Z0FM

CHASSIS STYLE
TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-13 Open TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-13 Open TYPE-1 Open TYPE-13 Open TYPE-1 Open TYPE-13 Open TYPE-1 TYPE-13 Open

DC REGEN PEAK CONT. CURRENT CURRENT

10 10 10 10 10 20 20 20 20 20 30 30 30 30 30 30 30 45 45 45 45 45 45 45 60 60 60 60 90 90 90 90 120 120 120 10 6 10 6 10 20 6 20 6 20 20 6 20 6 20 30 30 30 5 20 5 20 45 45 56 49 56 56 55 48 55 55 81 81 81

RATED HP BRAKING CONTINUOUS

2.3 2.3 2.3 2.3 2.3 4.5 4.5 4.5 4.5 4.5 6.8 6.8 6.8 6.8 6.8 6.8 6.8 10 10 10 10 10 10 10 14 14 14 14 20 20 20 20 27 27 27 2.3 1.3 2.3 1.3 2.3 4.5 1.3 4.5 1.3 4.5 4.5 1.3 4.5 1.3 4.5 6.8 6.8 7 1 4 1 4 10 10 13 11 13 13 12 11 12 12 18 18 18

MAX WATT LOSS

436 287 436 287 436 734 287 734 287 734 734 287 734 287 734 1107 1107 1107 287 734 287 734 1592 1592 1965 1741 1965 1965 1965 1741 1965 1965 2711 2711 2711

* an M in this place denotes a Current Meter is included, a 0 indicates Current Meter is not included.

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M3345
Table 6-2: Ratings and Specifications 380VAC

MODEL NUMBERS
M3345-30SMF0 M3345-30X*00 M3345-30X*F0 M3345-30BM00 M3345-30BMF0 M3345-31SMF0 M3345-31X*00 M3345-31X*F0 M3345-31BM00 M3345-31BMF0 M3345-32SMF0 M3345-32X*00 M3345-32X*F0 M3345-32BM00 M3345-32BMF0 M3345-32CMFM M3345-32Y*F0 M3345-34SMF0 M3345-34X*00 M3345-34X*F0 M3345-34BM00 M3345-34BMF0 M3345-34CMFM M3345-34Y*F0 M3345-3AWMFM M3345-3AY*FM M3345-3ACMFM M3345-3AZ*FM M3345-35WMFM M3345-35Y*FM M3345-35CMFM M3345-35Z*FM M3345-36VMFM M3345-36CMFM M3345-36Z0FM

CHASSIS STYLE
TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-13 Open TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-13 Open TYPE-1 Open TYPE-13 Open TYPE-1 Open TYPE-13 Open TYPE-1 TYPE-13 Open

DC REGEN PEAK CONT. CURRENT CURRENT

10 10 10 10 10 20 20 20 20 20 30 30 30 30 30 30 30 45 45 45 45 45 45 45 60 60 60 60 90 90 90 90 120 120 120 10 6 10 6 10 20 6 20 6 20 20 6 20 6 20 30 30 30 5 20 5 20 45 45 56 49 56 56 55 48 55 55 81 81 81

RATED HP BRAKING CONTINUOUS

7 7 7 7 7 15 15 15 15 15 22 22 22 22 22 22 22 33 33 33 33 33 33 33 45 45 45 45 67 67 67 67 89 89 89 7 4 7 4 7 15 4 15 4 15 15 4 15 4 15 22 22 23 4 15 4 15 33 33 41 36 41 41 41 36 41 41 60 60 60

MAX WATT LOSS

436 287 436 287 436 734 287 734 287 734 734 287 734 287 734 1107 1107 1107 287 734 287 734 1592 1592 1965 1741 1965 1965 1965 1741 1965 1965 2711 2711 2711

* an M in this place denotes a Current Meter is included, a 0 indicates Current Meter is not included.

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Table 6-3: Ratings and Specifications 460VAC

MODEL NUMBERS
M3345-40SMF0 M3345-40X*00 M3345-40X*F0 M3345-40BM00 M3345-40BMF0 M3345-41SMF0 M3345-41X*00 M3345-41X*F0 M3345-41BM00 M3345-41BMF0 M3345-42SMF0 M3345-42X*00 M3345-42X*F0 M3345-42BM00 M3345-42BMF0 M3345-42CMFM M3345-42Y*F0 M3345-44SMF0 M3345-44X*00 M3345-44X*F0 M3345-44BM00 M3345-44BMF0 M3345-44CMFM M3345-44Y*F0 M3345-4AWMFM M3345-4AY*FM M3345-4ACMFM M3345-4AZ*FM M3345-45WMFM M3345-45Y*FM M3345-45CMFM M3345-45Z*FM M3345-46VMFM M3345-46CMFM M3345-46Z0FM

CHASSIS STYLE
TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-13 Open TYPE-1 Open Open TYPE-13 TYPE-13 TYPE-13 Open TYPE-1 Open TYPE-13 Open TYPE-1 Open TYPE-13 Open TYPE-1 TYPE-13 Open

DC REGEN PEAK CONT. CURRENT CURRENT

10 10 10 10 10 20 20 20 20 20 30 30 30 30 30 30 30 45 45 45 45 45 45 45 60 60 60 60 90 90 90 90 120 120 120 10 6 10 6 10 20 6 20 6 20 20 6 20 6 20 30 30 30 5 20 5 20 45 45 56 49 56 56 55 48 55 55 81 81 81

RATED HP BRAKING CONTINUOUS

9 9 9 9 9 18 18 18 18 18 27 27 27 27 27 27 27 41 41 41 41 41 41 41 54 54 54 54 81 81 81 81 108 108 108 9 5 9 5 9 18 5 18 5 18 18 5 18 5 18 27 27 27 5 18 5 18 41 41 50 44 50 50 49 43 49 49 73 73 73

MAX WATT LOSS

436 287 436 287 436 734 287 734 287 734 734 287 734 287 734 1107 1107 1107 287 734 287 734 1592 1592 1965 1741 1965 1965 1965 1741 1965 1965 2711 2711 2711

* an M in this place denotes a Current Meter is included, a 0 indicates Current Meter is not included.

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M3345
A NOTE ON HP RATINGS
The Braking hp rating is dependent on the transistors, diodes, snubbers, and fuses provided with the module. It is a function of the DC bus amp rating and indicates the maximum hp that the module is designed to dissipate. Modules are able to provide full Braking hp for at least 60 seconds. Modules can provide less than full Braking hp for longer times. The Continuous hp rating is a function of package style, heatsinks, and cooling fans. This rating is always equal to or less than the Braking hp rating. For applications the following must exist:

Continuous Regen hp rating Required hp rating * Duty Cycle

6.2. WATT LOSS

Tables 6-1 thru 6-3 list the maximum Watt/Loss generated by each of the listed Regen units. When installing Regen units in an additional enclosure, consideration should be given to internal temperature rise. The Watt/Loss rating in these tables is based upon the maximum regen capability of each unit. Applications that do not utilize the full capacity may be calculated as follows:

hp*746*5%+100 = Watt Loss

Where hp is the average estimated regen horsepower

6.3. CERTIFICATIONS
There are presently no certifications for the M3345 Regen Unit. If certification is required, check with your integrator and/or panel shop for full system certification. The M3345 is constructed with industry guidelines and safety taken into consideration. If information is required for certification please contact Bonitron with your request.

6.4. FUSE/CIRCUIT BREAKER SIZING AND RATING

Only replace fuses with original type and rating. Due to the current limit control capability, blown fuses typically indicate internal device failure or severe transient absorption event. Table 6-4: Replacement Fuses

REGEN MODULE CURRENT RATING

10 Amps 20 Amps 30 Amps (B, S, X chx) 30 Amps (C, Y, Z chx) 45 Amps (B, S, X chx) 45 Amps (C, Y, Z chx) 60 Amps 90 Amps 120 Amps

AC LINE INPUT REPLACEMENT FUSE

A60Q15 A60Q25 A60Q30 FWP-35 A60Q40 FWP-50 FWP-70 FWP-100 FWP-125

DC BUS OUTPUT REPLACEMENT FUSE

A60Q15 A60Q25 FWP-40 FWP-40 FWP-50 FWP-60 FWP-80 FWP-100 FWP-125

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6.5. DIMENSIONS AND MECHANICAL DRAWINGS
Figure 6-1: M3345 S Chassis Dimensional Outline
(APPROX.)

4.000

Dwg #: 010074 Rev: 20070521

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M3345
Figure 6-2: M3345 W Chassis Dimensional Outline

30

Dwg #: 060230 Rev: 20070521

Users Manual
Figure 6-3: M3345 V Chassis Dimensional Outline

Dwg #: 070107 Rev: 20070521

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M3345
Figure 6-4: M3345 B Chassis Dimensional Outline

32

Dwg #: 920306 Rev: 20080310

Users Manual
Figure 6-5: M3345 B Chassis with Fan Dimensional Outline

Dwg #: 940040 Rev: 20080310

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M3345
Figure 6-6: M3345 C Chassis Dimensional Outline

34

Dwg #: 950191 Rev: 20091229

Users Manual
Figure 6-7: M3345 X Chassis Dimensional Outline

Dwg #: 920322 Rev: 20080311

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M3345
Figure 6-8: M3345 X Chassis with Fan Dimensional Outline

36

Dwg #: 940190 Rev: 20080311

Users Manual
Figure 6-9: M3345 Y Chassis Dimensional Outline

Dwg #: 950052 Rev: 20070928a

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M3345
Figure 6-10: M3345 Z Chassis Dimensional Outline

38

Dwg #: 950246 Rev: 20000927 mod

POWER CONTROL MODULE

di/dt LIMITER
1 OF 3

6.6. BLOCK DIAGRAM

A V LL
B 1

(+)

CTB A A
E1 TO OTHER PHASES

3 AC INPUT 50HZ OR 60HZ

B2

.33uf 1200V

6uf 1500V

DC BUS INPUT

CTC A
E2

(-)
B++ UN REG

Figure 6-11: Line Regen Functional Block Diagram

Dwg #: 000253 Rev: 20000830

POWER SUPPLY COM
B++ -10V UNREG. REF. +12V REG

CURRENT SENSING
LIMIT LED

OPTICALLY ISOLATED PHASE SENSING

ISOLATED GATE DRIVE 1 OF 3 I LIMIT

B1

TIMING LOGIC

E1

ON

B2 E2

ISOLATED BASE DRIVE

WHEN UNIT IS IN CURRENT LIMIT

BUS VOLTAGE SENSING

Users Manual

RUN

START-UP DELAY

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7. APPENDIX
7.1. APPLICATION NOTES 7.1.1. SIZING THE LINE REGENERATION CONTROL
Since the regeneration kit must direct energy from the DC bus back to the power system, it is sized for the amount of DC bus current which it must carry. To obtain the amount of DC bus current needed during deceleration; the load and motor inertias, desired change in RPM, and required stopping time must be known. With these application variables, the following calculations can be made to size the regeneration unit. Use the equation below to establish the torque required to decelerate or stop a rotating object.

T
where:

= = = = =

2 (WK ) N 308t

T WK2 N t

Torque required (lb-ft) Total inertia load to be decelerated (lb-ft) Change in speed (rpm) Time to decelerate load (sec)

Calculate the horsepower required at maximum speed.

P
where:

= = = =

TN 5250

P T N

Power (Hp) Torque (lb-ft) (calculated above) Maximum shaft speed (rpm)

Determine the DC bus current rating required for the regeneration module. IDC = P(1.2) for 460vac drives or: IDC = P(2.4) for 230vac drives where: P IDC = = Power (Hp) (calculated above) Regen Amps

7.1.2.

CALCULATING ENERGY SAVINGS

The regeneration kit directs energy from the mechanical load to the power distribution line, where the energy is available to other connected loads. These units provide system energy savings over dynamic braking kits, because the net energy required from the distribution system is reduced by the excess energy. Additional savings also occur when there is a need to provide air conditioning with a DB kit and from reduced time spent stopping loads. To calculate the savings; the regeneration duty cycle, the length of operation, the regen Hp, and the cost of energy must be known. With these application variables, the following calculation may be made to determine the cost savings:

$S

P(0.746)(t/T)(D)(H)($kW)

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M3345
where:

$S P D H t/T $kW

= = = = = =

Savings Power (Hp) Number of days Number of hours per day Percent on time Cost per kW

7.1.3.

SAVINGS EXAMPLE
A 20 Amp, Model M3345-41SMF0, has been selected for use in braking a high inertia centrifuge with the following characteristics. Calculate the energy savings over a DB kit.

P D H t/T $kW $S

= = = = = =

using:

20 Hp peak, 15 Hp average during deceleration 365 days 10 hours per day 5(on)/15(total) $0.08 per kW 15(0.746)(5/15)(365)(10)($0.08))

Savings per year is:

$S

$1,089.16

Using the regen module, the centrifuge customer is also able to reduce the braking time from 5 minutes to 1.5 minutes. This results in a 30% increase in throughput for the machine and produces additional cost savings for the customer.

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NOTES

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NOTES

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03/01/2011

521 Fairground Court Nashville, Tennessee 37211 (615) 244-2825 FAX (615) 244-2823 www.bonitron.com